Vapor-Permeable, Substantially Water-Impermeable Multilayer Article

ABSTRACT

This disclosure relates to an article (e.g., a vapor-permeable, substantially water-impermeable multilayer article) that can include a nonwoven substrate and a film supported by the nonwoven substrate. The film can include a polyolefin grafted with an anhydride, an acid, or an acrylate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 61/500,206 filed Jun. 23, 2011, which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

This disclosure relates to vapor-permeable, substantiallywater-impermeable multilayer articles, as well as related products andmethods.

BACKGROUND

Films that allow passage of gases at moderate to high transmission ratesare often called breathable. The gases most commonly used to demonstratea film's breathability are water vapor (also referred to herein asmoisture vapor or moisture) and oxygen. The moisture and oxygentransmission tests measure the mass or volume of a gas transportedacross the cross-section of a film in a given unit of time at a definedset of environmental conditions. Breathable films can be classified asmicroporous films or monolithic films (which are not porous).

A breathable film can be laminated onto a nonwoven substrate to form avapor-permeable, substantially water-impermeable multilayer article. Avapor-permeable, substantially water-impermeable multilayer article canrefer to an article that allows the passage of a gas but substantiallydoes not allow the passage of water.

SUMMARY

The inventors have unexpectedly discovered that a vapor-permeable,substantially water-impermeable multilayer article containing a modifiedpolyolefin (e.g., a polyolefin grafted with an anhydride, an acid, or anacrylate) either in a monolithic breathable film or as an intermediatelayer between a monolithic breathable film and a nonwoven substrate canhave improved adhesion between the monolithic breathable film and thenonwoven substrate while maintaining or improving the moisture vaportransmission rate (MVTR) of the entire article. Such an article can besuitable for use as a construction material (e.g., a housewrap or aroofwrap).

In one aspect, this disclosure features an article that includes anonwoven substrate and a film supported by the nonwoven substrate. Thefilm includes a first polymer containing a polyolefin grafted with ananhydride, an acid, or an acrylate.

In another aspect, this disclosure features an article that includes anonwoven substrate, a first film supported by the nonwoven substrate,and a second film. The first film is between the nonwoven substrate andthe second film and includes a first polymer containing a polyolefingrafted with an anhydride, an acid, or an acrylate. The second filmincludes a second polymer capable of absorbing and desorbing moistureand providing a barrier to aqueous fluids.

In still another aspect, this disclosure features a constructionmaterial (e.g., a housewrap or a roofwrap) that includes one of thearticles described above.

Embodiments can include one or more of the following optional features.

The polyolefin in the first polymer can include a homopolymer orcopolymer. For example, the polyolefin can include a polyethylene, apolypropylene, a poly(ethylene-co-vinyl acetate), or apoly(ethylene-co-acrylate).

The first polymer can include a low-density polyethylene grafted with ananhydride, a linear low-density polyethylene grafted with an anhydride,a high-density polyethylene grafted with an anhydride, a polypropylenegrafted with an anhydride, a poly(ethylene-co-acrylate) grated with ananhydride or an acid, and a poly(ethylene-co-vinyl acetate) grafted withan anhydride, an acid, or an acrylate.

The film containing the first polymer can include from about 1% byweight to about 20% by weight of this polymer.

The film containing the first polymer can further include a secondpolymer (e.g., from about 30% by weight to about 70% by weight of thesecond polymer) capable of absorbing and desorbing moisture andproviding a barrier to aqueous fluids. The second polymer can beselected from the group consisting of maleic anhydride block copolymers,glycidyl methacrylate block copolymers, polyether block copolymers,polyurethanes, polyethylene-containing ionomers, and mixtures thereof.Examples of the second polymer include poly(olefin-co-acrylate-co-maleicanhydride), poly(olefin-co-acrylate-co-glycidyl methacrylate), polyetherester block copolymers, polyether amide block copolymers, poly(etherester amide) block copolymers, and polyurethanes.

The film containing the first polymer can further include apolyetheramine (e.g., from about 1% by weight to about 10% by weight ofthe polyetheramine).

The film containing the first polymer can further include a vinylpolymer (e.g., from about 20% by weight to about 80% by weight of thevinyl polymer). The vinyl polymer can include a copolymer formed betweena first comonomer and a second comonomer, in which the first comonomercontains ethylene and the second commoner contains alkyl methacrylate,alkyl acrylate, or vinyl acetate. For example, the vinyl polymer caninclude a poly(ethylene-co-methyl acrylate), a poly(ethylene-co-vinylacetate), a poly(ethylene-co-ethyl acrylate), or apoly(ethylene-co-butyl acrylate).

When the first film containing the first polymer is between a nonwovensubstrate and a second film, the first film can include about 100% byweight of the first polymer. In such embodiments, the second film caninclude from about 20% by weight to about 100% by weight of the secondpolymer described above. The second film can further include the vinylpolymer described above (e.g., from about 20% by weight to about 80% byweight of the vinyl polymer).

The nonwoven substrate can include randomly disposed continuouspolymeric fibers, at least some of the fibers being bonded to oneanother.

The article can have a moisture vapor transmission rate of at leastabout 5 perms (about 32 g/m²/day at 23° C. and 50% Relative Humidity (RH%)).

The article can have a hydrostatic head of at least about 55 cm.

The adhesion between the substrate and the film containing the firstpolymer can be at least about 50 gram-force/in.

The film containing the second polymer is a monolithic film.

Other features and advantages will be apparent from the description,drawings, and claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a cross-sectional view of an exemplary vapor-permeable,substantially water-impermeable bilayer article.

FIG. 2 is a cross-sectional view of an exemplary vapor-permeable,substantially water-impermeable trilayer article.

FIG. 3 is a scheme illustrating an exemplary extruding process.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This disclosure relates to, for instance, an article (e.g., avapor-permeable, substantially water-impermeable multilayer article)containing a nonwoven substrate and a monolithic breathable filmsupported by the nonwoven substrate. In some embodiments, the monolithicbreathable film can include a first polymer (e.g., a modifiedpolyolefin) and a second polymer (e.g., a breathable polymer). In someembodiments, the article includes an intermediate layer containing thefirst polymer (e.g., a modified polyolefin) between the monolithicbreathable film containing the second polymer (e.g., a breathablepolymer) and the nonwoven substrate. The nonwoven substrate can beformed from polymeric fibers (e.g., fibers made from polyolefins).

Bilayer Article

FIG. 1 is a cross-sectional view of an exemplary vapor-permeable,substantially water-impermeable bilayer article 1 containing amonolithic breathable film 2 and a nonwoven substrate 4.

Monolithic Breathable Film 2

Film 2 can include a first polymer and a second polymer different fromthe first polymer.

In some embodiments, the first polymer includes a polyolefin graftedwith an anhydride (e.g., an anhydride containing one to ten carbonatoms), an acid (e.g., a carboxylic acid containing one to ten carbonatoms), or an acrylate (e.g., an acrylate containing one to ten carbonatoms). The anhydride can be an acyclic anhydride (e.g., aceticanhydride) or a cyclic anhydride (e.g., maleic anhydride). The acrylatecan be an alkyl acrylate (e.g., methyl acrylate, ethyl acrylate, orbutyl acrylate) or an alkyl methacrylate (e.g., methyl methacrylate,ethyl methacrylate, or butyl methacrylate). The anhydride, acid, oracrylate can be grafted onto a side chain and/or a main chain of thefirst polymer.

As used here, the term “polyolefin” refers to a homopolymer or acopolymer made from at least a linear or branched, cyclic or acyclicolefin monomer. Examples of polyolefin homopolymers includepolyethylene, polypropylene, polybutene, polypentene, andpolymethylpentene. A polyolefin copolymer can be formed from an olefinmonomer and one or more comonomers other than an olefine. Exemplarycomonomers that can be used to make polyolefin copolymers include vinylacetate or acrylates (e.g., alkyl acrylate such as methyl acrylate,ethyl acrylate, or butyl acrylate, or alkyl methacrylate such as methylmethacrylate, ethyl methacrylate, or butyl methacrylate). Exemplarypolyolefin copolymers include poly(ethylene-co-vinyl acetate)s andpoly(ethylene-co-acrylate)s. In some embodiments, exemplary polyethylenehomopolymers or copolymers include low-density polyethylene (e.g.,having a density from 0.910 g/cm² to 0.925 g/cm²), linear low-densitypolyethylene (e.g., having a density from 0.910 g/cm² to 0.935 g/cm²),and high-density polyethylene (e.g., having a density from 0.935 g/cm²to 0.970 g/cm²). High-density polyethylene can be produced bycopolymerizing ethylene with one or more C₄ to C₂₀ α-olefin comonomers.Examples of suitable α-olefin comonomers include 1-butene, 1-pentene,4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, and combinationsthereof. The high-density polyethylene can include up to 20 mole percentof the above-mentioned α-olefin comonomers.

Examples of the first polymer include a low-density polyethylene graftedwith an anhydride, a linear low-density polyethylene grafted with ananhydride, a high-density polyethylene grafted with an anhydride, apolypropylene grafted with an anhydride, a poly(ethylene-co-acrylate)grated with an anhydride or an acid, and a poly(ethylene-co-vinylacetate) grafted with an anhydride, an acid, or an acrylate. Commercialexamples of the first polymer include the BYNEL series of polymersavailable from E.I. du Pont de Nemours and Company, Inc. (Wilmington,Del.). In some embodiments, the BYNEL series of polymers have a relativelow MVTR, such as less than about 5 perms (about 32 g/m²/day at 23° C.and 50 RH %).

In some embodiments, film 2 can include at least about 1% (e.g., atleast about 2%, at least about 3%, at least about 5%, or at least about10%) by weight and/or at most about 20% (e.g., at most about 18%, atmost about 16%, at most about 14%, or at most about 12%) by weight ofthe first polymer. It is believed that the first polymer does not impartbreathability to a film and therefore incorporating such a polymer intoa film would reduce the breathability of the film. Unexpectedly, withoutwishing to be bound by theory, the inventors have discovered that film 2containing the first polymer in the amount mentioned above can haveimproved adhesion or compatibility between film 2 and nonwoven substrate4 while maintaining or even improving the MVTR of bilayer article 1.

The second polymer can be a breathable polymer. As used herein, “abreathable polymer” refers to a polymer capable of absorbing anddesorbing moisture and providing a barrier to aqueous fluids (e.g.,water). For example, a breathable polymer can absorb moisture from oneside of film 2 and release it to the other side of film 2, therebyallowing the moisture to be transported through the film. As thebreathable polymer can impart breathability to film 2, film 2 does notneed to include pores. As such, film 2 can be monolithic and not porous.

In some embodiments, the breathable polymer in film 2 can include maleicanhydride block copolymers, glycidyl methacrylate block copolymers,polyether block copolymers, polyurethanes, polyethylene-containingionomers, and mixtures thereof. Examples of maleic anhydride blockcopolymers include poly(olefin-co-acrylate-co-maleic anhydride), such aspoly(ethylene-co-acrylate-co-maleic anhydride). Commercial examples ofmaleic anhydride block copolymers include LOTADER MAH series of polymersavailable from Arkema (Philadelphia, Pa.) and BYNEL series of polymersavailable from E.I. du Pont de Nemours and Company, Inc. Examples ofglycidyl methacrylate block copolymers includepoly(olefin-co-acrylate-co-glycidyl methacrylate), such aspoly(ethylene-co-acrylate-co-glycidyl methacrylate). A commercialexample of a glycidyl methacrylate block copolymer is LOTADER GMA seriesof polymers available from Arkema.

Examples of polyether block copolymers include polyether ester blockcopolymers, polyether amide block copolymers, and poly(ether esteramide) block copolymers. Commercial examples of polyether ester blockcopolymers include ARNITEL series of polymers available from DSMEngineering Plastics (Evansville, Ind.), HYTREL series of polymersavailable from E.I. du Pont de Nemours and Company, Inc., and NEOSTARseries of polymers available from Eastman Chemical Company (Kingsport,Tenn.). A commercial example of a polyether amide block copolymer isPEBAX series of polymers available from Arkema.

A polyethylene-containing ionomer can include an ethylene copolymermoiety and an acid copolymer moiety. The ethylene copolymer moiety canbe formed by copolymerizing ethylene and a monomer selected from thegroup consisting of vinyl acetate, alkyl acrylate, and alkylmethacrylate. The acid copolymer moiety can be formed by copolymerizingethylene and a monomer selected from the group consisting of acrylicacid and methacrylic acid. The acidic groups in thepolyethylene-containing ionomer can be partially or fully converted tosalts that include suitable cations, such as Li⁺, Na⁺, K⁺, Mg²⁺, andZn²⁺. Examples of polyethylene-containing ionomers include thosedescribed in U.S. Patent Application Publication Nos. 2009/0142530 and2009/0123689.

Commercial examples of polyethylene-containing ionomers include ENTIRAand DPO AD 1099 series of polymers available from E.I. du Pont deNemours and Company, Inc.

Other suitable breathable polymers have been described in, for example,U.S. Pat. Nos. 5,800,928 and 5,869,414.

The amount of the second polymer in film 2 can vary depending on theintended uses of article 1. In some embodiments, film 2 can include anamount of the second polymer that is sufficiently large to impartdesired breathability to film 2 but sufficiently small to minimizemanufacturing costs. For example, the second polymer can be at leastabout 30% (e.g., at least about 35%, at least about 40%, at least about45%, or at least about 50%) and/or at most about 70% (e.g., at mostabout 65%, at most about 60%, at most about 55%, at most about 50%, orat most about 45%) of the total weight of film 2.

As breathable polymers can be expensive to manufacture, film 2 canoptionally include a vinyl polymer to reduce costs while maintaining theproperties of this film. The vinyl polymer can include a copolymerformed between a first comonomer and a second comonomer different fromthe first comonomer. Examples of the first comonomer can be olefins(such as ethylene or propylene). Examples of the second commoner caninclude alkyl methacrylate (e.g., methyl methacrylate, ethylmethacrylate, or butyl methacrylate), alkyl acrylate (e.g., methylacrylate, ethyl acrylate, or butyl acrylate), and vinyl acetate.Examples of suitable vinyl polymers include poly(ethylene-co-methylacrylate), poly(ethylene-co-vinyl acetate), poly(ethylene-co-ethylacrylate), and poly(ethylene-co-butyl acrylate). Commercial examples ofthe vinyl polymer include the LOTRYL series of polymers available fromArkema.

In some embodiments, film 2 can include at least about 20% (e.g., atleast about 25%, at least about 30%, at least about 35%, at least about40%, or at least about 50%) and/or at most about 80% (e.g., at mostabout 75%, at most about 70%, at most about 65%, at most about 60%, orat most about 55%) by weight of the vinyl polymer.

In some embodiments, film 2 can optionally include a polar compound,such as a polyetheramine. A commercial example of a polyetheramine isElastamine series of polymers available from Huntsman PerformanceProducts (The Woodlands, Tex.). In some embodiments, film 2 can includeat least about 1% (e.g., at least about 2%, at least about 3%, at leastabout 4%, or at least about 5%) by weight and/or at most about 10%(e.g., at most about 9%, at most about 8%, at most about 7%, at mostabout 6%, or at most about 5%) by weight of the polyetheramine. Withoutwishing to be bound by theory, it is believed that incorporating thepolar compound in film 2 can facilitate the transport of moisturethrough the film and thereby increase the MVTR of the film.

In some embodiments, the polar compound and the first polymer can beincluded in one composition before they are mixed with the othercomponents used to form film 2. A commercial example of such acomposition is PM14607 available from Techmer PM (Knoxville, Tenn.),which can include about 70% by weight of the first polymer and about 30%by weight of the polar compound.

In some embodiments, at least a portion (e.g., all) of the polarcompound can react with and be grafted onto the first polymer. In suchembodiments, the first polymer can include the polar groups (e.g., theamine groups) on the polar compound. Without wishing to be bound bytheory, it is believed that such a first polymer can both improve theadhesion between film 2 and nonwoven substrate 4 and improve the MVTR ofbilayer article 1.

In some embodiments, film 2 can have a thickness of at least about 5 μm(e.g., at least about 10 μm, at least about 15 μm, or at least about 20μm) and/or at most about 50 μm (e.g., at most about 45 μm, at most about40 μm, or at most about 35 μm).

Nonwoven Substrate 4

Nonwoven substrate 4 can include randomly disposed polymeric fibers, atleast some of the fibers being bonded to one another. As used herein,the term “nonwoven substrate” refers to a substrate containing one ormore layers of fibers that are bonded together, but not in anidentifiable manner as in a knitted or woven material.

Nonwoven substrate 4 can be formed from any suitable polymers. Exemplarypolymers that can be used to form nonwoven substrate 4 includepolyolefins and polyesters. Examples of suitable polyolefins includepolyethylene, polypropylene, and copolymers thereof, such as those usedin the first polymer in film 2 described above. Examples of suitablepolyesters include polyethylene terephthalate (PET), polybutyleneterephthalate (PBT), polytrimethylene terephthalate (PTT), polyethylenenaphthalate (PEN), polyglycolide or polyglycolic acid (PGA), polylactideor polylactic acid (PLA), polycaprolactone (PCL), polyethylene adipate(PEA), polyhydroxyalkanoate (PHA), and copolymers thereof.

Nonwoven substrate 4 can be formed from single component fibers, i.e.,fibers containing a polymer having a single chemical structure (e.g., apolymer described in the preceding paragraph such as a polyethylene, apolypropylene, a polyethylene terephthalate, or a copolymer thereof). Insome embodiments, nonwoven substrate 4 can include single componentfibers made from polymers having the same chemical structure butdifferent characteristics (e.g., molecular weights, molecular weightdistributions, density, or intrinsic viscosities). For example,substrate 4 can include a mixture of a low-density polyethylene and ahigh-density polyethylene. Such fibers are still referred to as singlecomponent fibers in this disclosure.

Nonwoven substrate 4 can also be formed from multicomponent fibers,i.e., fibers containing polymers with different chemical structures(such as two different polymers described above). For example, substrate4 can be formed from a mixture of a polypropylene and a polyethyleneterephthalate. In some embodiments, a multicomponent fiber can have asheath-core configuration (e.g., having a polyethylene terephthalate asthe core and a polypropylene as the sheath). In some embodiments, amulticomponent fiber can include two or more polymer domains in aconfiguration (e.g., a side-by-side configuration, a pie configuration,or an “islands-in-the-sea” configuration) different from the sheath-coreconfiguration.

In some embodiments, the surface of nonwoven substrate 4 can be formedof a polymer having a chemical structure similar to (e.g., the same typeas) or the same as the chemical structure of a polymer in the surface offilm 2. As an example, a polyolefin (e.g., a polyethylene or propylene)is the same type as and similar to a different polyolefin (e.g., apolyethylene or propylene). Without wishing to be bound by theory, it isbelieved that such two layers can have improved adhesion. For example,when nonwoven substrate 4 is formed from single component fibers, thefibers can be made from a polyolefin, which has a chemical structuresimilar to the first polymer in film 2. When nonwoven substrate 4 isformed of multicomponent fibers (e.g., having a sheath-coreconfiguration), the polymer (e.g., a polyolefin in the sheath) in thefibers that contacts film 2 can have a chemical structure similar tothat of the first polymer in film 2. Both examples described above canresult in a multilayer article with improved adhesion between the filmand the nonwoven substrate.

Nonwoven substrate 4 can be made by methods well known in the art, suchas a spunlacing, spunbonding, meltblowing, carding, air-through bonding,or calendar bonding process.

In some embodiments, nonwoven substrate 4 can be a spunbonded nonwovensubstrate. In such embodiments, nonwoven substrate 4 can include aplurality of random continuous fibers, at least some (e.g., all) ofwhich are bonded (e.g., area bonded or point bonded) with each otherthrough a plurality of intermittent bonds. The term “continuous fiber”mentioned herein refers to a fiber formed in a continuous process and isnot shortened before it is incorporated into a nonwoven substratecontaining the continuous fibers.

As an example, nonwoven substrate 4 containing single component fiberscan be made by using a spunbonding process as follows.

After the polymer for making single component fibers is melted, themolten polymer can be extruded from an extruding device. The moltenpolymer can then be directed into a spinneret with composite spinningorifices and spun through this spinneret to form continuous fibers. Thefibers can subsequently be quenched (e.g., by cool air), attenuatedmechanically or pneumatically (e.g., by a high velocity fluid), andcollected in a random arrangement on a surface of a collector (e.g., amoving substrate such as a moving wire or belt) to form a nonwoven web.In some embodiments, a plurality of spinnerets with different quenchingand attenuating capability can be used to place one or more (e.g., two,three, four, or five) layers of fibers on a collector to form asubstrate containing one or more layers of spunbonded (S) fibers (e.g.,an S, SS, or SSS type of substrate). In some embodiments, one or morelayers of meltblown (M) fibers can be inserted between the layers of theabove-described spunbonded fibers to form a substrate containing bothspunbonded and meltblown fibers (e.g., an SMS, SMMS, or SSMMS type ofsubstrate).

A plurality of intermittent bonds can subsequently be formed between atleast some of the fibers (e.g., all of the fibers) randomly disposed onthe collector to form a unitary, coherent, nonwoven substrate.Intermittent bonds can be formed by a suitable method such as mechanicalneedling, thermal bonding, ultrasonic bonding, or chemical bonding.Bonds can be covalent bonds (e.g., formed by chemical bonding) orphysical attachments (e.g., formed by thermal bonding). In someembodiments, intermittent bonds are formed by thermal bonding. Forexample, bonds can be formed by known thermal bonding techniques, suchas point bonding (e.g., using calender rolls with a point bondingpattern) or area bonding (e.g., using smooth calender rolls without anypattern). Bonds can cover between about 6 percent and about 40 percent(e.g., between about 8 percent and about 30 percent or between about 22percent and about 28 percent) of the total area of nonwoven substrate 4.Without wishing to be bound by theory, it is believed that forming bondsin substrate 4 within these percentage ranges allows elongationthroughout the entire area of substrate 4 upon stretching whilemaintaining the strength and integrity of the substrate.

Optionally, the fibers in nonwoven substrate 4 can be treated with asurface-modifying composition after intermittent bonds are formed.Methods of applying a surface-modifying composition to the fibers havebeen described, for example, in U.S. Provisional Patent Application No.61/294,328.

Nonwoven substrate 4 thus formed can then be used to form bilayerarticle 1 described above. A nonwoven substrate containingmulticomponent fibers can be made in a manner similar to that describedabove. Other examples of methods of making a nonwoven substratecontaining multicomponent fibers have been described in, for example,U.S. Provisional Patent Application No. 61/294,328.

Trilayer Article

FIG. 2 is a cross-sectional view of an exemplary vapor-permeable,substantially water-impermeable trilayer article 10 containing amonolithic breathable film 12, an intermediate film 16, and a nonwovensubstrate 14.

Intermediate film 16 can include the first polymer described inconnection with bilayer article 1 above (i.e., a polyolefin grafted withan anhydride, an acid, or an acrylate). In such embodiments,intermediate layer 16 can be made substantially from the first polymer(i.e., containing about 100% of the first polymer).

In some embodiments, intermediate film 16 can have a thickness of atleast about 0.2 μm (e.g., at least about 0.4 μm, at least about 0.6 μm,at least about 0.8 μm, or at least about 1 μm) and/or at most about 5 μm(e.g., at most about 4 μm, at most about 3 μm, at most about 2 μm, or atmost about 1 μm). It is believed that a film containing the firstpolymer is not breathable and therefore incorporating such a polymer asan intermediate layer between a breathable film and a nonwoven substratecan reduce the breathability of the article. Without wishing to be boundby theory, the inventors have discovered that intermediate film 16having a thickness mentioned above can improve the adhesion between film12 and nonwoven substrate 14 while still maintaining the MVTR oftrilayer article 10 at an acceptable level.

Monolithic breathable film 12 can include the second polymer describedin connection with bilayer article 1 above (i.e., a breathable polymer).In some embodiments, the second polymer can be at least about 20% (e.g.,at least about 30%, at least about 40%, at least about 50%, or at leastabout 60%) and/or at most about 100% (e.g., at most about 90%, at mostabout 80%, at most about 70%, at most about 60%, or at most about 50%)of the total weight of film 12.

In some embodiments, monolithic breathable film 12 can optionallyinclude the vinyl polymer described in connection with bilayer article 1above. In some embodiments, film 12 can include at least about 20%(e.g., at least about 25%, at least about 30%, at least about 35%, atleast about 40%, or at least about 50%) and/or at most about 80% (e.g.,at most about 75%, at most about 70%, at most about 65%, at most about60%, or at most about 55%) by weight of the vinyl polymer.

In some embodiments, monolithic breathable film 12 can have a thicknessof at least about 10 μm (e.g., at least about 12 μm, at least about 14μm, at least about 16 μm, at least about 18 μm, or at least about 20 μm)and/or at most about 30 μm (e.g., at most about 28 μm, at most about 26μm, at most about 24 μm, at most about 22 μm, or at most about 20 μm).In some embodiments, the ratio between the thickness of film 12 and thethickness of intermediate film 16 can be at most about 150:1 (e.g., atmost about 100:1, at most about 50:1, at most about 20:1, or at mostabout 10:1) and/or at least about 2:1 (e.g., at least about 5:1, atleast about 10:1, at least about 15:1, or at least about 20:1).

Nonwoven substrate 14 can be the same or have the same characteristicsas nonwoven substrate 4 described in connection with bilayer article 1above.

Method of Making Multilayer Article 1 or 10

Multilayer article 1 or 10 can be made by the methods known in the artor the methods described herein. An exemplary method of making trilayerarticle 10 is described below. Bilayer article 1 can be made in asimilar manner except that the nonwoven substrate is coated with onlyone layer, instead of two layers.

In some embodiments, trilayer article 10 can be made by applying films12 and 16 onto nonwoven substrate 14. Films 12 and 16 can be appliedonto nonwoven substrate 14 by co-extruding (e.g., cast extrusion) asuitable composition for film 12 (e.g., a composition containing thesecond polymer) and a suitable composition for film 16 (e.g., acomposition containing the first polymer) at an elevated temperature toform two layers onto nonwoven substrate 14. In some embodiments, thejust-mentioned compositions can be co-extruded (e.g., by tubularextrusion or cast extrusion) to form a web, which can be cooled (e.g.,by passing through a pair of rollers) to form a precursor two-layerstructure. Trilayer article 10 can then be formed by attaching theprecursor structure to nonwoven substrate 14 by using, for example, anadhesive (e.g., a spray adhesive, a hot melt adhesive, or a latex basedadhesive), thermal bonding, ultra-sonic bonding, or needle punching.

FIG. 3 is a scheme illustrating an exemplary process for making trilayerarticle 10 described above. As shown in FIG. 3, a suitable compositionfor film 16 (e.g., a composition containing the first polymer) can befed into an inlet 26 of an extruder hopper 24. The composition can thenbe melted and mixed in a screw extruder 20. The molten mixture can bedischarged from extruder 20 under pressure through a heated line 22 to aflat film die 38. A suitable composition for film 12 (e.g., acomposition containing a breathable polymer) can be fed into an inlet 36of an extruder hopper 34. The composition can then be melted and mixedin a screw extruder 30. The molten mixture can be discharged fromextruder 30 under pressure through a heated line 32 to flat film die 38to be co-extruded with the molten mixture for film 16. Co-extruded melt40 discharging from flat film die 38 can be coated on nonwoven substrate14 supplied from roll 50 such that film 16 is between nonwoven substrate14 and film 12. The coated substrate can then enter a nip formed betweenrolls 52 and 56, which can be maintained at a suitable temperature(e.g., between about 10-120° C.). Passing the coated substrate throughthe nip formed between cooled rolls 52 and 56 can quench co-extrusionmelt 40 while at the same time compressing co-extrusion melt 40 so thatit forms a contact on nonwoven substrate 14. In some embodiments, roll52 can be a smooth rubber roller with a low-stick surface coating whileroll 56 can be a metal roll. A textured embossing roll can be used toreplace metal roll 56 if a multilayer article with a textured film layeris desired. When co-extrusion melt 40 is cooled, it forms films 16 and12 laminated onto nonwoven substrate 14. The laminate thus formed canthen be collected on a collection roll 54 to form trilayer article 10.In some embodiments, the surface of nonwoven substrate 14 can be coronaor plasma treated before it is coated with co-extrusion melt 40 toimprove the adhesion between nonwoven substrate 14 and films 16 and 12.

In some embodiments, trilayer article 10 formed above can be embossed(e.g., by using a calendering process). For example, trilayer article 10can be embossed by passing through a pair of calender rolls in which oneroll has an embossed surface and the other roll has a smooth surface.Without wishing to be bound by theory, it is believed that an embossedmultilayer article can have a large surface area, which can facilitatevapor transmission through the multilayer article. In some embodiments,at least one (e.g., both) of the calender rolls is heated, e.g., bycirculating a hot oil through the roll, during the embossing process.

Properties of Multilayer Article 1 or 10

In some embodiments, multilayer article 1 or 10 can have a suitable MVTRbased on its intended uses. As used herein, the MVTR values are measuredaccording to ASTM E96-A. For example, multilayer article 1 or 10 canhave a MVTR of at least about 5 perms (about 32 g/m²/day when measuredat 23° C. and 50 RH %) (e.g., at least about 6 perms (about 39 g/m²/dayat 23° C. and 50 RH %), at least about 8 perms (about 52 g/m²/day at 23°C. and 50 RH %), or at least about 10 perms (about 65 g/m²/day at 23° C.and 50 RH %)) and/or at most about 20 perms (about 130 g/m²/day whenmeasured at 23° C. and 50 RH %) (e.g., at most about 17 perms (about 110g/m²/day at 23° C. and 50 RH %), at most about 15 perms (about 97g/m²/day at 23° C. and 50 RH %), or at most about 12 perms (about 77g/m²/day at 23° C. and 50 RH %)). For instance, multilayer article 10can have a MVTR of between 8 perms (about 52 g/m²/day at 23° C. and 50RH %) and 15 perms (about 97 g/m²/day at 23° C. and 50 RH %).

In some embodiments, multilayer article 1 or 10 can have a sufficienttensile strength in the machine direction and/or the cross-machinedirection. The tensile strength is determined by measuring the tensileforce required to rupture a sample of a sheet material. The tensilestrength mentioned herein is measured according to ASTM D5034 and isreported in pounds. In some embodiments, multilayer article 1 or 10 canhave a tensile strength of at least about 40 pounds (e.g., at leastabout 50 pounds, at least about 60 pounds, at least about 70 pounds, orat least about 80 pounds) and/or at most about 160 pounds (e.g., at mostabout 150 pounds, at most about 140 pounds, at most about 130 pounds, orat most about 120 pounds) in the machine direction. In some embodiments,multilayer article 1 or 10 can have a tensile strength of at least about35 pounds (e.g., at least about 40 pounds, at least about 50 pounds, atleast about 60 pounds, or at least about 70 pounds) and/or at most about140 pounds (e.g., at most about 130 pounds, at most about 120 pounds, atmost about 110 pounds, or at most about 100 pounds) in the cross-machinedirection.

As a specific example, when multilayer article 1 or 10 has a unit weightof 1.25 ounce per square yard (osy), it can have a tensile strength ofat least about 40 pounds (e.g., at least about 45 pounds, at least about50 pounds, at least about 55 pounds, or at least about 60 pounds) and/orat most about 100 pounds (e.g., at most about 95 pounds, at most about90 pounds, at most about 85 pounds, or at most about 80 pounds) in themachine direction, and at least about 35 pounds (e.g., at least about 40pounds, at least about 45 pounds, at least about 50 pounds, or at leastabout 55 pounds) and/or at most about 95 pounds (e.g., at most about 90pounds, at most about 85 pounds, at most about 80 pounds, or at mostabout 75 pounds) in the cross-machine direction.

In some embodiments, multilayer article 1 or 10 can have a sufficientelongation in the machine direction and/or the cross-machine direction.Elongation is a measure of the amount that a sample of a sheet materialwill stretch under tension before the sheet breaks. The term“elongation” used herein refers to the difference between the lengthjust prior to breaking and the original sample length, and is expressedas a percentage of the original sample length. The elongation valuesmentioned herein are measured according to ASTM D5034. For example,multilayer article 1 or 10 can have an elongation of at least about 5%(e.g., at least about 10%, at least about 20%, at least about 30%, atleast about 35%, or at least about 40%) and/or at most about 100% (e.g.,at most 90%, at most about 80%, or at most about 70%) in the machinedirection. As another example, multilayer article 1 or 10 can have anelongation of at least about 5% (e.g., at least about 10%, at leastabout 20%, at least about 30%, at least about 40%, or at least about50%) and/or at most about 100% (e.g., at most about 90%, at most about80%, or at most about 70%) in the cross-machine direction.

In some embodiments, multilayer article 1 or 10 can have a sufficienthydrostatic head value so as to maintain sufficient waterimpermeability. As used herein, the term “hydrostatic head” refers tothe pressure of a column of water as measured by its height that isrequired to penetrate a given material and is determined according toAATCC 127. For example, multilayer article 1 or 10 can have ahydrostatic head of at least about 55 cm (e.g., at least about 60 cm, atleast about 70 cm, at least about 80 cm, at least about 90 cm, or atleast about 100 cm) and/or at most about 900 cm (e.g., at most about 800cm, at most about 600 cm, at most about 400 cm, or at most about 200cm).

Without wishing to be bound by theory, it is believed that, in trilayerarticle 10, the adhesion between film 16 and nonwoven substrate 14 issignificantly higher than that between film 12 and nonwoven substrate.For example, the adhesion between film 16 and nonwoven substrate 14 canbe at least about 50 gram-force/in (e.g., at least about 100gram-force/in, at least about 200 gram-force/in, at least about 300gram-force/in, at least about 500 gram-force/in, at least about 1,000gram-force/in, or at least about 1,500 gram-force/in). By contrast, theadhesion between film 12 and nonwoven substrate 14 can be, in someembodiments, at most about 200 gram-force/in (e.g., at most about 150gram-force/in, at most about 100 gram-force/in, at most about 50gram-force/in, or at most about 10 gram-force/in). As a result, film 16can improve the adhesion between nonwoven substrate 14 and film 12.

Multilayer article 1 or 10 can be used in a consumer product with orwithout further modifications. Examples of such consumer productsinclude construction materials, such as a housewrap or a roofwrap. Otherexamples include diapers, adult incontinence devices, feminine hygieneproducts, medical and surgical gowns, medical drapes, and industrialapparels.

While certain embodiments have been disclosed, other embodiments arealso possible.

In some embodiments, an effective amount of various additives can beincorporated in a film or the nonwoven substrate in multilayer article 1or 10. Suitable additives include pigments, antistatic agents,antioxidants, ultraviolet light stabilizers, antiblocking agents,lubricants, processing aids, waxes, coupling agents for fillers,softening agents, thermal stabilizers, tackifiers, polymeric modifiers,hydrophobic compounds, hydrophilic compounds, anticorrosive agents, andmixtures thereof. In certain embodiments, additives such as polysiloxanefluids and fatty acid amides can be included to improve processabilitycharacteristics.

Pigments of various colors can be added to multilayer article 1 or 10 sothat the resultant article is substantially opaque and exhibits uniformcolor. For example, multilayer article 1 or 10 can have a sufficientamount of pigments to produce an opacity of at least about 85% (e.g., atleast about 90%, at least about 95%, at least about 98%, or at leastabout 99%). Suitable pigments include, but are not limited to, antimonytrioxide, azurite, barium borate, barium sulfate, cadmium pigments(e.g., cadmium sulfide), calcium chromate, calcium carbonate, carbonblack, chromium(III) oxide, cobalt pigments (e.g., cobalt(II)aluminate), lead tetroxide, lead(II) chromate, lithopone, orpiment,titanium dioxide, zinc oxide and zinc phosphate. Preferably, the pigmentis titanium dioxide, carbon black, or calcium carbonate. The pigment canbe about 1 percent to about 20 percent (e.g., about 3 percent to about10 percent) of the total weight of a film or the nonwoven substrate inmultilayer article 1 or 10. Alternatively, the pigment can be omitted toprovide a substantially transparent multilayer article.

In some embodiments, certain additives can be used to facilitatemanufacture of multilayer article 1 or 10. For example, antistaticagents can be incorporated into a film or the nonwoven substrate tofacilitate processing of these materials. In addition, certain additivescan be incorporated in multilayer article 1 or 10 for specific endapplications. For example, anticorrosive additives can be added ifmultilayer article 1 or 10 is to be used to package items that aresubject to oxidation or corrosion. As another example, metal powders canbe added to provide static or electrical discharge for sensitiveelectronic components such as printed circuit boards.

Each film and the nonwoven substrate in multilayer article 1 or 10 canalso include a filler. The term “filler” can include non-reinforcingfillers, reinforcing fillers, organic fillers, and inorganic fillers.For example, the filler can be an inorganic filler such as talc, silica,clays, solid flame retardants, Kaolin, diatomaceous earth, magnesiumcarbonate, barium carbonate, magnesium sulfate, calcium sulfate,aluminum hydroxide, zinc oxide, magnesium hydroxide, calcium oxide,magnesium oxide, alumina, mica, glass powder, ferrous hydroxide,zeolite, barium sulfate, or other mineral fillers or mixtures thereof.Other fillers can include acetyl salicylic acid, ion exchange resins,wood pulp, pulp powder, borox, alkaline earth metals, or mixturesthereof. The filler can be added in an amount of up to about 60 weightpercent (e.g., from about 2 to about 50 weight percent) of a film or thenonwoven substrate in multilayer article 1 or 10.

In some embodiments, the surface of a film or the nonwoven substrate inmultilayer article 1 or 10 can be at least partially treated to promoteadhesion. For example, the surface can be corona charged or flametreated to partially oxidize the surface and enhance surface adhesion.Without wishing to be bound by theory, it is believed that multilayerarticle 1 or 10 having enhanced surface adhesion can enable printing onits surface using conventional inks Ink jet receptive coating can alsobe added to the surface of multilayer article 1 or 10 to allow printingby home or commercial ink-jet printers using water based or solventbased inks.

In some embodiments, a multilayer article described herein can includemultiple (e.g., two, three, four, or five) films supported by nonwovensubstrate 14, at least two of the films are films 12 and 16 described inFIG. 2 above. The additional films can be made by one or more of thematerials used to prepare film 12 or 16 described above or othermaterials known in the art. In some embodiments, nonwoven substrate 14can be disposed between two of the multiple films. In some embodiments,all of the films can be disposed on one side of nonwoven substrate 14.

The following examples are illustrative and not intended to be limiting.

Example 1

The following four bilayer articles were prepared: (1) TYPAR (i.e., apolypropylene spunbonded nonwoven substrate available from Fiberweb,Inc) having a unit weight of 1.9 ounce per square inch and coated with amonolithic breathable film containing 40 wt % PEBAX MV3000, 51 wt %LOTRYL 20MA08 (i.e., an ethyl methacrylate), 5 wt % BYNEL 22E757, 2 wt %TiO₂ (10SAM0242 available from Standridge Color Corporation (SocialCircle, Ga.)), and 2 wt % UV stabilizer (10743-08 available fromColortech Inc. (Morristown, Tenn.)); and (2) a bilayer article similarto bilayer article (1) except that the monolithic breathable filmincluded 40 wt % PEBAX MV3000, 46 wt % LOTRYL 20MA08, 5 wt % PM14607which included 70 wt % BYNEL 22E757 and 30 wt % Elastamine), 5 wt %BYNEL 22E757, 2 wt % TiO₂, and 2 wt % UV stabilizer; (3) a bilayerarticle similar to bilayer article (1) except that the monolithicbreathable film included 40 wt % PEBAX MV3000, 41 wt % LOTRYL 20MA08, 10wt % PM14607, 5 wt % BYNEL 22E757, 2 wt % TiO₂, and 2 wt % UVstabilizer; and (4) a bilayer article similar to bilayer article (1)except that the monolithic breathable film included 40 wt % PEBAXMV3000, 36 wt % LOTRYL 20MA08, 15 wt % PM14607, 5 wt % BYNEL 22E757, 2wt % TiO₂, and 2 wt % UV stabilizer. The bilayer articles were formed byextruding the monolithic breathable film onto TYPAR at 520° F.

Bilayer articles (1)-(4) were evaluated for their MVTR, hydrostatichead, and adhesion properties. The adhesion was measured as follows:9-inch long samples were prepared by adhering a 2-inch wide housewraptape over the coating (folding over one end of the tape onto itself toprovide a tab for gripping) to prevent elongation of the coating. Thepeel adhesion of the samples was then measured by using an Instron orIMASS peel tester with a 5-pound load cell. A 180 degree peel angel wasused with a rate of separation of 12 in/minute. The test results aresummarized in Table 1 below.

TABLE 1 Film Weight MVTR Hydrostatic (gsm) Substrate (Perm) head (cm)Article (1) 20 TYPAR 1.9 8 536 Article (2) osy 8.5 712 Article (3) (10den) 9.1 412 Article (4) 14.1 51

As articles (2)-(4) had higher amounts of BYNEL (i.e., a breathablepolymer with a relatively low MVTR) than article (1), one would expectthat they would exhibit lower breathability than article (1).Unexpectedly, the results in Table 1 showed that, with an increasingamount of Elastamine, articles (2)-(4) exhibited an increasing MVTR eventhough they contained an increasing amount of BYNEL.

Example 2

The following three multilayer articles were prepared: (1) a bilayerarticle containing TYPAR having a unit weight of 1.9 ounce per squareinch and coated with a monolithic breathable film containing 70 wt %NEOSTAR FN005, 26 wt % LOTRYL 20MA08 (i.e., an ethyl methacrylate), 2 wt% TiO₂ (10SAM0242), and 2 wt % UV stabilizer (10743-08); and (2) atrilayer article having the same TYPAR substrate and the monolithicbreathable film as bilayer article (1), but further including anintermediate film containing 100 wt % BYNEL 22E757 between themonolithic breathable film and TYPAR; and (3) a trilayer article similarto trilayer article (2) except that the monolithic breathable filmincluded 96 wt % NEOSTAR FN005, 2 wt % TiO₂ (10SAM0242), and 2 wt % UVstabilizer (10743-08). In articles (2) and (3), the ratio of thethickness between the monolithic breathable film and the intermediatefilm was about 4:1. In addition, the total weight of the films inarticles (2) and (3) were 18 gsm, while the weight of the film inarticle (1) was 28 gsm.

Bilayer article (1) was formed by extruding the monolithic breathablefilm onto TYPAR at 480° F. Trilayer articles (2) and (3) were formed byco-extruding the monolithic breathable film and the intermediate filmonto TYPAR. The extruder temperatures for the monolithic breathable filmand the intermediate film were 480° F. and 520° F., respectively.

Multilayer articles (1)-(3) were evaluated for their MVTR, hydrostatichead, and adhesion properties between the TYPAR and the intermediatefilm. The test results are summarized in Table 2 below.

TABLE 2 Film Weight MVTR Hydrostatic Adhesion (gsm) Substrate (Perm)head (cm) (gram-force/in) Article (1) 28 TYPAR 11 713 <20 Article (2) 181.9 osy 14 283 100 Article (3) 18 (10 den) 15.3 528 57

As articles (2) and (3) had a smaller film weight and therefore asmaller film thickness than article (1), one would expect that theywould exhibit lower adhesion between the films and the TYPAR substrate.Unexpectedly, the results showed that articles (2) and (3) (each ofwhich included an intermediate film) exhibited significantly higheradhesion between the films and the TYPAR substrate than that found inarticle (1). Further, at a reduced film weight, articles (2) and (3)exhibited an improved MVTR compared to article (1).

Example 3

The following three multilayer articles were prepared: (1) a bilayerarticle containing TYPAR having a unit weight of 1.9 ounce per squareinch and coated with a monolithic breathable film containing 100 wt %ENTIRA AD 1099; and (2) a trilayer article having the same TYPARsubstrate and the monolithic breathable film as bilayer article (1), butfurther including an intermediate film containing 100 wt % BYNEL E418between the monolithic breathable film and TYPAR, the total weight ofthe films in article (2) being 30 gsm; and (3) a trilayer articlesimilar to trilayer article (2) except that the total weight of thefilms in article (3) was 25 gsm. In articles (2) and (3), the thicknessof the monolithic breathable film and the intermediate film was 25 μmand 2 μm, respectively.

Bilayer article (1) was formed by extruding the monolithic breathablefilm onto TYPAR at 455° F. Trilayer articles (2) and (3) were formed byco-extruding the monolithic breathable film and the intermediate filmonto TYPAR. The extruder temperatures for the monolithic breathable filmand the intermediate film were 455° F. and 520° F., respectively.

Multilayer articles (1)-(3) were evaluated for their MVTR, hydrostatichead, and adhesion properties. The adhesion was measured by using thesame method described in Example 2. The test results are summarized inTable 3 below.

TABLE 3 Film Weight MVTR Hydrostatic Adhesion (gsm) Substrate (Perm)head (cm) (gram-force/in) Article (1) 25 TYPAR 15 825 <30 Article (2) 301.9 osy 6.2 847 >250 Article (3) 25 (10 den) 9.5 765 >250

The results showed that articles (2) and (3) (each of which included anintermediate film) exhibited significantly higher adhesion between thefilms and the TYPAR substrate. Further, at the same film weight as thatof article (1), article (3) unexpectedly exhibited an acceptable MVTReven though it included an intermediate film containing a polymer with arelatively low MVTR.

Other embodiments are in the claims.

1. An article, comprising: a nonwoven substrate; and a film supported bythe nonwoven substrate, the film comprising a first polymer thatcomprises a polyolefin grafted with an anhydride, an acid, or anacrylate.
 2. The article of claim 1, wherein the polyolefin comprises ahomopolymer or copolymer.
 3. The article of claim 1, wherein thepolyolefin comprises a polyethylene, a polypropylene, apoly(ethylene-co-vinyl acetate), or a poly(ethylene-co-acrylate).
 4. Thearticle of claim 1, wherein the first polymer comprises a low-densitypolyethylene grafted with an anhydride, a linear low-densitypolyethylene grafted with an anhydride, a high-density polyethylenegrafted with an anhydride, a polypropylene grafted with an anhydride, apoly(ethylene-co-acrylate) grated with an anhydride or an acid, and apoly(ethylene-co-vinyl acetate) grafted with an anhydride, an acid, oran acrylate.
 5. The article of claim 1, wherein the film comprises fromabout 1% by weight to about 20% by weight of the first polymer.
 6. Thearticle of claim 1, wherein the film further comprises a second polymercapable of absorbing and desorbing moisture and providing a barrier toaqueous fluids.
 7. The article of claim 6, wherein the second polymer isselected from the group consisting of maleic anhydride block copolymers,glycidyl methacrylate block copolymers, polyether block copolymers,polyurethanes, polyethylene-containing ionomers, and mixtures thereof.8. The article of claim 6, wherein the second polymer is selected fromthe group consisting of poly(olefin-co-acrylate-co-maleic anhydride),poly(olefin-co-acrylate-co-glycidyl methacrylate), polyether ester blockcopolymers, polyether amide block copolymers, poly(ether ester amide)block copolymers, and polyurethanes.
 9. The article of claim 6, whereinthe second polymer is selected from the group consisting of polyetherester block copolymers, poly(ethylene-co-acrylate-co-maleic anhydride),and poly(ethylene-co-acrylate-co-glycidyl methacrylate).
 10. The articleof claim 6, wherein the film comprises from about 30% by weight to about70% by weight of the second polymer.
 11. The article of claim 10,wherein the film further comprises a polyetheramine.
 12. The article ofclaim 11, wherein the film comprises from about 1% by weight to about10% by weight of the polyetheramine.
 13. The article of claim 1, whereinthe film further comprises a vinyl polymer.
 14. The article of claim 13,wherein the vinyl polymer comprises a copolymer formed between a firstcomonomer and a second comonomer, the first comonomer comprisesethylene, and the second commoner comprises alkyl methacrylate, alkylacrylate, or vinyl acetate.
 15. The article of claim 14, wherein thevinyl polymer comprises a poly(ethylene-co-methyl acrylate), apoly(ethylene-co-vinyl acetate), a poly(ethylene-co-ethyl acrylate), ora poly(ethylene-co-butyl acrylate).
 16. The article of claim 13, whereinthe film comprises from about 20% by weight to about 80% by weight ofthe vinyl polymer.
 17. The article of claim 1, wherein the nonwovensubstrate comprises randomly disposed continuous polymeric fibers, atleast some of the fibers being bonded to one another.
 18. The article ofclaim 1, wherein the article has a moisture vapor transmission rate ofat least about 5 perms.
 19. The article of claim 1, wherein the articlehas a hydrostatic head of at least about 55 cm.
 20. The article of claim1, wherein the adhesion between the substrate and the film is at leastabout 200 gram-force/in.
 21. The article of claim 1, wherein the film isa monolithic film.
 22. A construction material, comprising the articleof claim
 1. 23. The construction material of claim 22, wherein theconstruction material is a housewrap or a roofwrap.
 24. An article,comprising: a nonwoven substrate; a first film supported by the nonwovensubstrate, the first film comprising a first polymer that comprises apolyolefin grafted with an anhydride, an acid, or an acrylate; and asecond film comprising a second polymer capable of absorbing anddesorbing moisture and providing a barrier to aqueous fluids, the firstfilm being between the nonwoven substrate and the second film.
 25. Thearticle of claim 24, wherein the polyolefin comprises a homopolymer orcopolymer.
 26. The article of claim 24, wherein the polyolefin comprisesa polyethylene, a polypropylene, a poly(ethylene-co-vinyl acetate), or apoly(ethylene-co-acrylate).
 27. The article of claim 24, wherein thefirst polymer comprises a low-density polyethylene grafted with ananhydride, a linear low-density polyethylene grafted with an anhydride,a high-density polyethylene grafted with an anhydride, a polypropylenegrafted with an anhydride, a poly(ethylene-co-acrylate) grated with ananhydride or an acid, and a poly(ethylene-co-vinyl acetate) grafted withan anhydride, an acid, or an acrylate.
 28. The article of claim 24,wherein the first film comprises about 100% by weight of the firstpolymer.
 29. The article of claim 24, wherein the second polymer isselected from the group consisting of maleic anhydride block copolymers,glycidyl methacrylate block copolymers, polyether block copolymers,polyurethanes, polyethylene-containing ionomers, and mixtures thereof.30. The article of claim 29, wherein the second polymer is selected fromthe group consisting of poly(olefin-co-acrylate-co-maleic anhydride),poly(olefin-co-acrylate-co-glycidyl methacrylate), polyether ester blockcopolymers, polyether amide block copolymers, poly(ether ester amide)block copolymers, and polyurethanes.
 31. The article of claim 30,wherein the second polymer is selected from the group consisting ofpolyether ester block copolymers, poly(ethylene-co-acrylate-co-maleicanhydride), and poly(ethylene-co-acrylate-co-glycidyl methacrylate). 32.The article of claim 24, wherein the second film comprises from about20% by weight to about 100% by weight of the second polymer.
 33. Thearticle of claim 24, wherein the second film further comprises a vinylpolymer.
 34. The article of claim 33, wherein the vinyl polymercomprises a copolymer formed between a first comonomer and a secondcomonomer, the first comonomer comprises ethylene, and the secondcommoner comprises alkyl methacrylate, alkyl acrylate, or vinyl acetate.35. The article of claim 34, wherein the vinyl polymer comprises apoly(ethylene-co-methyl acrylate), a poly(ethylene-co-vinyl acetate), apoly(ethylene-co-ethyl acrylate), or a poly(ethylene-co-butyl acrylate).36. The article of claim 34, wherein the second film comprises fromabout 20% by weight to about 80% by weight of the vinyl polymer.
 37. Thearticle of claim 34, wherein the nonwoven substrate comprises randomlydisposed continuous polymeric fibers, at least some of the fibers beingbonded to one another.
 38. The article of claim 24, wherein the articlehas a moisture vapor transmission rate of at least about 5 perms. 39.The article of claim 24, wherein the article has a hydrostatic head ofat least about 55 cm.
 40. The article of claim 24, wherein the adhesionbetween the substrate and the first film is at least about 50gram-force/in.
 41. The article of claim 24, wherein the first or secondfilm is a monolithic film.
 42. A construction material, comprising thearticle of claim
 24. 43. The construction material of claim 42, whereinthe construction material is a housewrap or a roofwrap.
 44. The articleof claim 1, wherein: the article has a moisture vapor transmission rateof at least about 5 perms; the article has a hydrostatic head of atleast about 55 cm; and the adhesion between the substrate and the firstfilm is at least about 200 gram-force/in.
 45. The article of claim 24,wherein: the article has a moisture vapor transmission rate of at leastabout 5 perms; the article has a hydrostatic head of at least about 55cm; and the adhesion between the substrate and the first film is atleast about 50 gram-force/in.